Sequential combustor and method for operating the same

ABSTRACT

The present invention generally relates to a sequential combustor for a gas turbine having second and/or subsequent stages of a re-heat, sequential or axially-staged combustion system. A variation in Mach number along the flow path can be used to control static temperature variation, which in turn influences the progress of auto-ignition reactions that eventually lead to the onset of combustion.

TECHNICAL FIELD

The present invention generally relates to a sequential combustor for agas turbine. The invention additionally refers to a method for operatingthe same.

BACKGROUND

With reference to FIG. 1, it is depicted a scheme of a sequentialcombustor according to the known art. The combustor comprises twodistinct zones: the burner, or a premixing section (where the fuel andoxidant are premixed), and a combustor chamber where the combustiontakes place. The inlet oxidant entering into the combustor is relativelyhot, in some cases ca. 1250K-1300K. At these temperatures, the fuelinjected into the burner auto-ignites. In order to achieve low emissionsit is important that the fuel and the oxidant are very well premixedprior to combustion. The auto-ignition delay time determines the timeallowable for premixing.

FIG. 2 shows the auto-ignition delay time for natural gas as a functionof temperature.

At the temperature of 1250K-1300K, the auto-ignition delay time isapproximately 1-2 msec for a typical natural gas. It is the latter thatlimits the allowable inlet temperature. A mixing time of 1-2 msec is thecapability of present state-of-the-art systems, when operated at areasonable pressure drop, for which there is a limit, due to the engineperformance and to combustor system management concerns.

It is to be noted, that if the inlet temperature is increased, the COturndown characteristics of the gas turbine are improved, as indicatedin FIG. 3.

It would therefore be advantageous, if the inlet temperature wereincreased without resulting in an increased pressure drop.

Downstream of the burner is a sudden expansion into the combustorchamber. Such state-of-the-art geometry results in recirculation zones,the purpose of which is to provide flame stabilization. Theoretically,as the combustion occurs through auto-ignition, there would be no needfor flame stabilization. However, practically, the inlet boundaryconditions fluctuate and vary, such that relatively large fluctuationsin auto-ignition delay time may occur. Without some means of flamestabilization, it would be not possible to keep the flame within thedesired location. The recirculation zones, necessary to stabilize theflame, however, are very dissipative. Therefore, in order to limitpressure losses, the velocities have to be kept relatively low,corresponding to a Mach number in the order of 0.1, prior to combustion.As well known, the Mach number is defined as the velocity of the flow ofgas divided by the value of the local speed of sound. Additionally, thecombustion process is then controlled by fluid dynamic transport, withinthe recirculation zones and the shear layers surrounding them. Instate-of-the-art systems, these timescales are of the order ofmilliseconds, even though the chemical processes are more than an orderof magnitude smaller (CO oxidation is of the order 0.1 m sec and theheat release chemical kinetics is of the order 0.01 m sec).

It is to be noted that if the flow velocity were greater, the combustorcross section could be smaller. This would allow for a more compactcombustor and easier integration of the combustion process into a nozzleguide vane. Additionally, if the combustion process were not stabilizedby fluid dynamic structures, such as recirculation zones, and thereforerate limited by fluid dynamic processes, the combustor residence timecould be significantly shorter. This would allow yet greater compactnessof the combustor, yielding benefits for cost and system management, butalso allowing a reduction in NOx emissions, particularly at very highfiring temperatures.

Re-heat (or after burner) systems for aero-engine applications broadlywork on the same principles described above. Fuel is injected into theexhaust from the turbine. The combustion, which is typically initiatedthrough auto-ignition, is stabilized by recirculation zones, which aretypically induced by V gutters. The length of the exhaust duct has to belong enough for the flame to propagate from these recirculation zones,across the entire width of then duct. Combustion is therefore ratelimited by fluid dynamic processes.

It is to be noted that if the combustion would be allowed to progress atchemical kinetic timescales, the exhaust duct could be shorted, allowinga saving in weight.

SUMMARY OF THE INVENTION

It is an object of the present invention to solve the aforementionedtechnical problems by providing a sequential combustor as substantiallydefined according to independent claim 1.

Moreover, a further object of the present invention is to provide amethod for operating a sequential combustor as defined in dependentclaim 14.

According to various aspects of the invention, it is disclosed a newsequential combustor and a novel method for operating the same bycontrolling auto-ignition reactions and stabilizing the subsequent heatrelease reactions. Specifically, the invention concerns the 2nd and/orsubsequent stages of a re-heat, sequential or axially-staged combustionsystem. According to the invention, variation in Mach number along theflow path is used to control static temperature variation, which in turninfluences the progress of auto-ignition reactions that eventually leadto the onset of combustion.

There are two distinct ideas to be pursued where the variation of statictemperature is utilised. These can be applied either together, toexploit the advantages of both, or the first idea can be applied on itsown.

According to an aspect of the invention, the flow of fuel and oxidantwithin the premixing section is accelerated, such that the statictemperature drops, thereby slowing down the auto-ignition reactions. Asa consequence, CO turndown can advantageously be extended, and that thedownstream combustor can be made more compact.

According to preferred embodiments of the invention, after the highvelocity premixing section the flow is accelerated still further, andthen it is decelerated along a well-controlled, aerodynamically designedpath. The resulting gradient in static temperature is then utilised tostabilize/anchor the auto-ignition flame. This replaces knownmethodologies that utilise recirculation zones. Advantageously, thisallows the combustion to occur at a higher Mach number, for a givenpressure loss, enabling the system to be more compact (i.e. having asmaller cross section) which gives advantage for cooling flow demand andcomponent life. Another benefit is that combustion can be completedwithin a shorter residence time. This results in lower NOx emissions,particularly at high firing temperatures. The positive statictemperature gradients in the region where the flame is located make thatreheat flame more stable with respect to perturbations that can lead toheat release fluctuations. The sequential combustor is therefore morerobust against thermo acoustic oscillations. A smaller combustor volumeand cross section also enable an easier integration of the combustorinto the nozzle guide vanes. This allows the removal of a leakage plane,as well as reduction in cost and weight.

A sequential combustor according to the invention may be placeddownstream of a first combustor, but upstream of the turbine stages, asin the case of sequential combustor within a constant pressuresequential combustion (CPSC) system, as shown in FIG. 4.

Alternatively, it may be placed in between turbine stages. However as inthe case of standard sequential combustors, a number of sequentialcombustors, utilising the present invention, can be placed betweenseveral turbine stages, as shown in FIG. 5.

Alternatively, a sequential combustor according to the invention may beplaced at the exit of the turbine stages, in the exhaust duct forreheating (afterburning) applications, as used in some aero-enginesystem. See scheme depicted in FIG. 6.

According to an aspect of the invention, it is provided a sequentialcombustor for a gas turbine, comprising a premixing section and acombustion chamber arranged downstream of the premixing section, thepremixing section being configured to receive and premix a flow ofoxidant and fuel, wherein the premixing section is arranged along one ormore convergent ducts.

According to a preferred aspect of the invention, the premixing sectioncomprises a diffuser section, arranged downstream each convergent duct.

According to a preferred aspect of the invention, the convergent ductsare passages formed between a plurality of vanes.

According to a preferred aspect of the invention, each vane comprises arounded leading edge.

According to a preferred aspect of the invention, the rounded leadingedge has a radius of curvature which is a fourth or less of a distance Dbetween two adjacent vanes.

According to a preferred aspect of the invention, each vane has aconverging side wall having an angle α of duct contraction substantiallyequal to or less than 30°, along the duct.

According to a preferred aspect of the invention, the duct contractionangle α is substantially equal to 20°.

According to a preferred aspect of the invention, the premixing sectioncomprises mixing devices distributed along facing sidewalls of adjacentvanes.

According to a preferred aspect of the invention, the premixing sectioncomprises fuel injectors.

According to a preferred aspect of the invention, the premixing sectioncomprises an airfoil element positioned along a first portion of theconverging duct between adjacent vanes, wherein the airfoil element hasa rounded leading edge and a trailing edge, and wherein the fuelinjectors are provided at the proximity of the trailing edge.

According to a preferred aspect of the invention, the combustor chambercomprises a diffuser section formed by one or more diverging ducts.

According to a preferred aspect of the invention, the divergent ductsare passages formed between the plurality of vanes and wherein eachdivergent duct is arranged downstream of a convergent duct, theconvergent and divergent ducts being formed by a common vane-shapedpassage.

According to a preferred aspect of the invention, the divergent duct hasan expansion vane angle β equal to 9° or greater.

According to a preferred aspect of the invention, expansion vane angle βis substantially equal to 15°.

According to a further aspect of the invention, it is also provided amethod for operating a sequential combustor for a gas turbine, thesequential combustor comprising a premixing section and a combustionchamber arranged downstream of the premixing section, the premixingsection being configured to receive and premix a flow of oxidant andfuel and arranged along one or more convergent ducts, wherein the flowof oxidant and fuel is admitted within said one or more convergent ductsand therein accelerated to a velocity correspondent to a Mach numbersubstantially equal to 0.5 or greater.

According to a preferred aspect of the invention, the combustion chambercomprises a diffuser section comprising one or more diverging ductsformed between a plurality of vanes and wherein each divergent duct isarranged downstream a convergent duct, the convergent and divergentducts being formed by a common vane-shaped passage, wherein the flow ofoxidant and fuel is decelerated along the one or more divergent ductsand reaches a velocity correspondent to a Mach number in the region of0.3 prior to combustion.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects, advantages and other features of the present invention willbecome more apparent upon reading of the following non-restrictivedescription of preferred embodiments thereof, given for the purpose ofexemplification only, with reference to the accompany drawing, throughwhich similar reference numerals may be used to refer to similarelements, and in which:

FIG. 1 shows an arrangement of a combustor according to the known art;

FIG. 2 is a graph showing the auto-ignition delay time for a natural gasas a function of temperature;

FIG. 3 is a graph showing the CO emissions as a function of apost-combustion gas temperature from a sequential combustor, and theimpact of burner inlet temperature is indicated;

FIGS. 4-6 depict different exemplary functional schemes where asequential combustor according to the invention may be arranged;

FIGS. 7-9 show respectively a schematic, a top and a perspective view ofa sequential combustor according to a first exemplary embodiment of thepresent invention;

FIG. 10 depicts a graph showing the decrease of static temperature as afunction of the Mach number;

FIGS. 11-13 show respectively a schematic, a top and a perspective viewof a sequential combustor according to a second exemplary embodiment ofthe present invention;

FIGS. 14-19 show different details of the sequential combustor accordingto the present invention.

Preferred and non-limiting embodiments will be now described in detailwith reference to the above referenced drawings.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIG. 7, it is shown a schematic side section view of asequential combustor 100 according to a first embodiment of theinvention.

In particular, the sequential combustor 100 comprises a premixingsection, or burner, 101, configured to receive and premix a flow ofoxidant and fuel, and a combustion chamber 102 arranged downstream thepremixing section 101. As indicated in the figure, the premixing sectionis arranged along a convergent duct 105.

In this case, the combustion chamber 102 is of a conventional type, andthe flow of oxidant and fuel, after the burner experiences a firstdiffuser section 108 and then a sudden expansion into a chamber 102. Incombustion chamber 102 recirculation zones 104 are generated which helpstabilizing a flame indicated in the drawing with numeral reference 103.

With reference to following FIGS. 8 and 9, it is shown the sequentialcombustor 100 respectively in side section and perspective views, wherethe flow of oxidant (coming from a first upstream combustor, not shown)is indicated with arrows F. Sequential combustor 100 may comprise aplurality of converging ducts 105, into which oxidant and fuel enters,which are passages 105 formed between a series of vanes 106. Downstreamthe premixing section is the combustion chamber 102, common for all thepassages 105, including recirculation zones 104 which help stabilizingflames 103.

Advantageously, the flow of oxidant and fuel in the premixing section101 is accelerated to a velocity corresponding to a Mach number whichhas a value of approximately 0.5 or greater. This causes the statictemperature to decrease, as shown by the graph in following FIG. 10.

The reduction in static temperature prolongs the auto-ignition delaytime (as shown in the above mentioned FIG. 2). In particular, thetemperature drop inside the premixing region may be up to 200K,resulting in ten times increase in ignition delay time. However theturndown capability of the combustor depends upon the total temperaturein the burner, provided that the Mach number in the combustor issufficiently reduced. This difference between total and statictemperature can then be utilized to extend the turndown characteristicsof the combustor, for a given temperature, and therefore auto-ignitiondelay time, within which the burner operates.

In the premixing section 101, the flow of oxidant and fuel after theconverging passage 105 passes through the final diffuser section 108before expanding into the combustion chamber 102.

With now reference to next FIG. 11, it is depicted a side sectionschematic view of a sequential combustor 200 according to a secondpreferred embodiment of the present invention. In this secondembodiment, the premixing section 101 is the same one disclosed withreference to the first embodiment: the flow of oxidant and fuel in thepremixing section is accelerated through the converging duct 105, andthen experiences the diffuser 108 prior to entering into a combustionchamber 202.

Differently, in this case, the combustion chamber 202 comprises adiffuser section formed by a diverging duct 202. Hence, in this secondembodiment the flow of oxidant and fuel, after the premixing section 101following a converging first portion, continues its path along thediffuser 108 and then, seamlessly, into the diverging duct 202, where aflame 203 is produced. A very rapid flow deceleration is required toprovide the necessary temperature gradient for the flame stabilization.As a non-limiting exemplary embodiment, such a rapid flow divergence isadvantageously achieved through an expansion of the duct characterisedby an expansion angle β which is equal to 9° or greater. Preferably, theexpansion angle β is approximately in the order of 15°. Additionally,splitter plates (not shown) may be used to further increase the diffuserangle up to 45°.

With now reference to the next FIGS. 12 and 13, it is shown thesequential combustor 200 respectively in side section and perspectiveviews, where the flow of oxidant (coming from a first upstreamcombustor, not shown) is indicated with arrows F. Similarly to the firstembodiment, sequential combustor 200 may comprise a plurality ofdivergent passages formed between a series of vanes 206 arranged insequence. In this case, the divergent passage 202, where the combustiontakes place, is positioned downstream the convergent and divergentpassages 105 and 108, where the oxidant is accelerated and premixed withthe fuel. Therefore, convergent and divergent passages 105, 108 and 202are in this case formed in a common vane-shaped passage. This way, theflow of oxidant and fuel travels across the sequential combustor 200experiencing a typical convergent-divergent duct. Vanes 206, and inparticular their shape allowing the formation of suchconvergent-divergent passages, are best seen in perspective view of FIG.13.

The divergent passage 202, where the combustion takes place, focuses itsadvantageous effect on the flame stabilization zone. As described above,prior to this zone the flow is accelerated to a Mach number, typicallyequal or greater than 0.5. The flow of oxidant and fuel is thendecelerated which results in an increasing static temperature withdownstream distance. The initial acceleration, which occurs in theregion where fuel and oxidant mixing is being completed, leads to areduction in static temperature, which slows the auto-ignitionreactions. The subsequent increase in static temperature, in thedeceleration (divergent) section, re-triggers the auto-ignitionreactions, which in turn leads to the onset of combustion. In order tolimit pressure losses, the Mach number prior to combustion isapproximately 0.3.

Within the present invention, recirculation zones are not required.Instead, the location of the flame is stabilized through a positivetemperature gradient along the flow path, driven by the reduction inMach number from its maximum value. Under these circumstances, thoughthe flame location will still move as inlet boundary conditions change,the movement is restricted by virtue of the temperature gradient.Additionally the sequential combustor according to the invention has anoperating mode which is self-stabilizing against perturbations. Forexample, if the inlet boundary conditions are perturbed such that theauto-ignition delay time increases, the flame will tend to movedownstream. However that moves the flame into a region of lower Machnumber, and thus higher temperature, which rather leads to a reductionof the ignition delay time.

This counteracts the effect of the perturbation. The reverse is alsotrue. If the boundary conditions are perturbed such that theauto-ignition delay time is reduced, the flame tends to move upstream.

This however moves the flame towards a higher Mach number, and a lowertemperature and hence it tends to rather increase the auto-ignitiondelay time and move the flame downstream.

Therefore, the impact of the perturbation is always counteracted.

Given the absence of recirculation zones, the pressure drop coefficientcan be reduced and a higher Mach number can be allowed, approx. 0.3prior to combustion, whilst still limiting the pressure loss toacceptable levels. This allows the cross section of the combustor to belower.

In the present state-of-the-art combustors, the reliance uponrecirculation zones to stabilize/anchor the combustion means that thecombustion process is rate-limited by fluid dynamic mixing, as theanchoring/stabilization is enabled by the exchange of mass/heat from therecirculation zones to the main flow. This requires the combustionsystems to be sized such that the residence time is of severalmilliseconds. In the present case, combustion is not limited by mixingprocesses and can proceed at a rate given by the chemical kineticreactions. In the case where CO burnout to very low levels is necessary,the required residence time is one order of magnitude lower than thepresent state-of-the-art. In the case where CO emissions from the gasturbine can be allowed to rise, the required residence time is more thantwo orders of magnitude lower than the present state-of-the-art.

A smaller cross section of the combustor, allowed by combusting withinhigher velocity flow without a corresponding increase in length and dueto small residence time required for the combustion process, leads to amore compact combustor. This has benefits regarding costs, airflowmanagement and maintenance, and makes it easier to achieve mechanicalintegrity goals. Further simplification is afforded by the removal offront panels or other bluff structures that are necessary to supportrecirculation zones, with associated reduction in material (e.g. metaland thermal barrier coating that constitute the front panel) and coolingflows necessary to keep its temperature to acceptable levels.

An additional benefit of the low residence time required in thepost-combustion gas is the limitation of the rate of formation of oxidesof Nitrogen (NOx), particularly at high temperatures.

This therefore allows firing temperatures of gas turbines to increase,without a corresponding increase in NOx.

Within the present invention, the flame stabilization relies on controlof the static temperature variations due to control of the flow velocity(Mach number variations) such that combustion can take place in adedicated combustor as well as in the turbine vanes: shaping the vanesas herein described can provide the required flowacceleration/deceleration which permits the integration of multiplestages.

With now reference to FIG. 14, two perspective views from differentangles of a converging passage 105 are depicted. The converging passage105 is formed between adjacent vanes, where facing sidewalls 60 and 70are illustrated. Converging ducts 105, and more in general the premixingsection of the sequential combustor, are the same for the first andsecond embodiments, so the following description applies to both.

Along the converging passage 105, fuel injectors 30 and mixing devices20 are provided on sidewalls 60 and 70. Mixing devices are preferably inthe form of protruding elements which act as turbulence generators inorder to promote the mixing of oxidant and fuel. In the example of FIG.14, fuel injectors 30 are provided on sidewalls 60 and 70 downstreammixing devices 20.

As an alternative, illustrated in the next FIG. 15, the premixingsection comprises a central airfoil element positioned along theconvergent duct 105 and between adjacent vanes. The airfoil element 10is shaped such to aerodynamically interact with the incoming flow ofoxidant and to provide flow conditioning, and in practise separatespassage 105 into two separate top and bottom convergent passages. Forthis purpose, airfoil element 10 includes a rounded leading edge and atrailing edge, the latter reaching a downstream area in the duct withrespect to mixing devices 20. In this case, fuel injectors 30 areprovided in the proximity of the trailing edge of the airfoil element10.

With reference to following FIG. 16, a schematic side section view of aconvergent passage 105 shows a preferred geometry.

In particular, each vane has a rounded leading edge 40, wherein a radiusof curvature R thereof is preferably equal to a fourth of a distance Dmeasured between axes of two adjacent vanes. Radius R may also belesser.

The same geometric proportion may be chosen for the rounded leading edgeof airfoil element (not shown in the figure). Moreover, facing sidewalls60, 70 which form the converging passage 105 present an angle ofcontraction a, along the duct, which has a maximum value ofapproximately 30° and a preferred value substantially equal to 20°.

Next FIG. 17 illustrates a preferred geometry of a mixing device 20.Mixing device 20 comprises a delta-wing vortex generator havingconstruction angles γ and ω, respectively in a section view and in a topview of the combustor, equal to 15° or greater, and in any case notexceeding 30°. Additionally, mixing device 20 presents a height H whichis preferably equal to a fourth of the distance D between two adjacentvanes, and does not exceed a third of said distance. The number ofmixing devices 20 is generally arranged according to the premixingsection geometry, preferably without exceeding fifteen devices on eachvane sidewall 60, 70.

Additional mixing devices may also be distributed onto the airfoilelement, as depicted in following FIG. 18. Such additional mixingdevices may be delta-wing devices as disclosed above, or in the shape oflobes 61, where a penetration angle α is preferably comprised within arange 10°-22°, and a ratio between a pitch κ and a height H is within arange 0.4-2.5, and preferably close to unity. Mixing devices 20, aspresented in FIG. 17, are essentially triangle-shaped. However, mixingdevices may also be of irregular shapes, as illustrated, as non-limitingexamples, in FIG. 19.

Turbulence enhancement devices may also be implemented on the walls ofthe diffusor sections, where combustion takes place. These devices maytake the form of reverse delta wings, turbulators, ribs or flow ejectorusing higher-pressure compressor air.

While the invention has been described in detail in connection with onlya limited number of embodiments, it should be readily understood thatthe invention is not limited to such disclosed embodiments. Rather, theinvention can be modified to incorporate any number of variations,alterations, substitutions or equivalent arrangements not heretoforedescribed, but which are commensurate with the spirit and scope of theinvention. Additionally, while various embodiments of the invention havebeen described, it is to be understood that aspects of the invention mayinclude only some of the described embodiments. Accordingly, theinvention is not to be seen as limited by the foregoing description, butis only limited by the scope of the appended claims.

1. Sequential combustor for a gas turbine, comprising: a premixingsection and a combustion chamber arranged downstream of the premixingsection, said premixing section being configured to receive and premix aflow of oxidant and fuel, said premixing section being arranged alongone or more convergent ducts.
 2. Sequential combustor according to claim1, wherein said one or more convergent ducts are passages formed betweena plurality of vanes.
 3. Sequential combustor according to claim 2,wherein each vane comprises: a rounded leading edge.
 4. Sequentialcombustor according to claim 3, wherein said rounded leading edge has aradius of curvature which a fourth or less of a distance D between twoadjacent vanes.
 5. Sequential combustor according to claim 2, whereineach vane has a converging side wall having an angle α of ductcontraction substantially equal to 30° or less along the duct. 6.Sequential combustor according to claim 5, wherein said duct contractionangle α is substantially equal to 20°.
 7. Sequential combustor accordingto claim 1, wherein said premixing section comprises: mixing devicesdistributed along facing sidewalls of adjacent vanes.
 8. Sequentialcombustor according to claim 1, wherein said premixing sectioncomprises: fuel injectors.
 9. Sequential combustor according to claim 8,wherein said premixing section comprises: an airfoil element positionedalong said converging duct between adjacent vanes, said airfoil elementhaving a rounded leading edge and a trailing edge, said fuel injectorsbeing provided at the proximity of said trailing edge.
 10. Sequentialcombustor according to claim 1, wherein said combustor chambercomprises: a diffuser section formed by one or more diverging ducts. 11.Sequential combustor according to claim 2, wherein said one or moredivergent ducts are passages formed between said plurality of vanes andwherein each divergent duct is arranged downstream a convergent duct,said convergent and divergent ducts formed by a common vane-shapedpassage.
 12. Sequential combustor according to claim 11, wherein saiddivergent duct has an expansion vane angle β equal to 9° or greater. 13.Sequential combustor according to claim 1, wherein said premixingsection comprises: a diffuser section arranged downstream eachconvergent duct.
 14. Method for operating a sequential combustor for agas turbine, the sequential combustor having a premixing section and acombustion chamber arranged downstream of the premixing section, saidpremixing section being configured to receive and premix a flow ofoxidant and fuel and arranged along one or more convergent ducts,wherein the method comprises: admitting a flow of oxidant and fuelwithin said one or more convergent ducts for acceleration to a velocitycorrespondent to a Mach number substantially equal to 0.5 or greater.15. Method for operating a sequential combustor for a gas turbineaccording to claim 14, wherein the combustion chamber includes adiffuser section formed by one or more diverging ducts, said one or moredivergent ducts formed between a plurality of vanes and wherein eachdivergent duct is arranged downstream a convergent duct, said convergentand divergent ducts being formed by a common vane-shaped passage,wherein the method comprises: decelerating the flow of oxidant and fuelalong said one or more divergent duct to a velocity correspondent to aMach number in the region of 0.3 prior to combustion.